Catalytic surfaces and coatings for the manufacture of petrochemicals

ABSTRACT

This disclosure describes a coating composition comprising: Mn x O y , MnCr 2 O 4 , or combinations thereof in a first region of a coating having a first thickness, wherein x and y are integers between 1 and 7; and X 6 W 6 (Si z , C 1-z ) in a second region of the coating having a second thickness, wherein X is Ni or a mixture of Ni and one or more transition metals and z ranges from 0 to 1.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation application of U.S. patentapplication Ser. No. 13/906,865 filed May 31, 2013, (now U.S. Pat. No.8,906,822) which claims priority to U.S. Provisional Patent ApplicationNo. 61/654,659, filed on Jun. 1, 2012, both of which are incorporatedherein by reference in their entirety.

BACKGROUND

From a materials perspective, the manufacture of olefins by hydrocarbonsteam pyrolysis has not changed very much since originallycommercialized, except to progressively operate at higher operatingtemperatures with overall greater cracking severity. Process containmentor furnace coils have evolved in alloy composition and properties overthe last 60+ years to sustain the higher temperatures and lowerfeedstock residence times. This has resulted in an increase in unwantedor negative catalytic reactions at the coil surfaces and othercarbon-based fouling mechanisms; for example, carbon or coke build-up bysurface-catalyzed “filamentous” coke-make. Overall, these foulingmechanisms reduce furnace and plant efficiencies, and significantlyincrease furnace maintenance costs.

Efforts aimed towards mitigating the problem have made some progressover the last quarter century. These efforts include better alloys andcoil surfaces, feedstock additives and inhibitors, and coil coatings.For example, in the 1980s and 1990s, several promising coatingtechnologies were developed and commercialized aimed at rendering theinternal surfaces of furnace coils chemically inert to the pyrolysis orcracking process (i.e., shutting-down catalytic or filamentouscoke-make). Overall, these coatings were able to provide someimprovements in furnace run-lengths from a typical baseline of ˜20-40days. The use of inert coatings increased run lengths by a factor of 2-3times. The run lengths, however, rarely exceeded ˜100 days on-line. Thesuccess of some of these coatings prompted some steel producers todevelop and commercialize novel alloys away from industry-standardchromia-forming austenitic stainless steels whose surfaces exhibitrelatively low temperature stability under cracking conditions (<1050°C. (1922° F.)). The newly developed steels were engineered with highertemperature-stable surfaces through the use of alumina-formers.

Hydrocarbon processing in the manufacture of petrochemicals is carriedout in processing equipment that includes tubing, piping, fittings andvessels of broad geometries and alloy compositions. These components aregenerally made of ferrous-based alloys designed to provide adequatechemical, mechanical and physical properties for process containment,and resistance to a range of materials degradation processes. Incommercial applications operating above 500° C., austenitic stainlesssteels are often used ranging from 300 series alloys through to35Cr—45Ni—Fe alloys, with the level of nickel and chromium in the alloygenerally increasing with operating temperature. Above 800° C., asub-group of these austenitic steels are used and are collectively knownas high-temperature alloys (HTAs) or heat-resistant alloys. These HTAsteels range from 25Cr—20Ni—Fe (HK40) through to 35Cr—45Ni—Fe (orhigher), plus alloying additives in cast form, and similar compositionsin wrought form. In general, stainless steel surfaces are prone to theformation of filamentous (catalytic) carbon or coke and the accumulationof amorphous (or gas-phase) coke, with their relative contribution tothe total coke-make being defined by the petrochemical manufacturingprocess, feedstock, and the operating conditions. Filamentous cokeformation is well documented and has been shown to be catalyzed bytransition metal surface species, their oxides, and compounds thereof,with iron and nickel-based species being the major catalysts present instainless steels.

The broad commercial use of stainless steel alloys, especially HTAs ispartially due to their ability of generating and re-generating aprotective rhombohedral chromia (Cr₂O₃) scale for protection. Thesesteels are collectively known as “chromia-formers” with the scalebelieved to provide both corrosion protection and resistance tofilamentous (catalytic) coke formation. It is generally accepted that abulk alloy level of 13-17 wt % Cr is required to generate and sustain acontiguous and protective chromia scale. The overall protection providedby the chromia is good to excellent within its operating limitations.One critical limitation pertinent to hydrocarbon processing is thatunder highly carburizing conditions (as for example with a carbonactivity a_(c)≧1 during steam pyrolysis of aliphatic hydrocarbonfeedstock) and temperatures greater than approximately 1050° C. (orlower depending on actual conditions), the chromia is converted tochromium carbides, leading to volume expansion, embrittlement, andsubsequent loss of protection. Additionally, under highly oxidizingconditions (as for example, during furnace start-up and decoking), abovea critical temperature, the chromia is converted to CrO₃ andvolatilized. Therefore, there is great commercial value in a base alloywith the mechanical and physical properties of the HTAs currently used,but with a protective coating and surface that overcomes the limitationsof the chromia scale and provides greater protective benefits forreducing carbon-based fouling and corrosion.

In the manufacture of major petrochemicals, the generation of a chromiascale on process components such as furnace coils is often critical inachieving and perhaps exceeding furnace design capacity. As an example,in steam pyrolysis of ethane to produce ethylene, the operating sequenceis typically 20-90 days online of production, followed by 1-4 daysoffline for decoking. This industry “optimum” capitalizes on theprotection provided by the chromia scale, while operating, as best as isfeasible, within the chemical and mechanical limitations that thechromia scale imposes on the process.

Efforts to reduce filamentous (catalytic) coking have involved the useof coatings, pre-oxidation of components, chemical additives, or acombination thereof, all aimed at rendering the surfacecatalytically-inert to filamentous coke-make. Examples of coatedproducts are based on the teachings of U.S. Pat. No. 5,873,951 andCanadian patent 2,227,396 aimed at generating an alumina layer incontact with the process stream. Canadian patent 2,227,396 also teachesthe use of a coating aimed at generating a chromia layer at theoutermost surface. U.S. Pat. No. 4,297,150 teaches the use of CVDprocesses to deposit coatings aimed at providing a silica layer incontact with the process stream. The use of chemical additives in somepetrochemical industries is broad. As an example, most commercialoperations manufacturing olefins by steam pyrolysis add a sulfur-basedcompound (such as DMS or DMDS) to the feedstock at levels of a few ppmto several hundred ppm to poison catalytic surface sites. Alternatively,other efforts have tried to passivate the surface through the additionof various proprietary chemical additives to the feedstock (see U.S.Pat. Nos. 4,613,372, 4,804,487, 4,863,892, 5,015,358, 5,565,087,5,616,236, and 5,446,229). Generally, the level of commercial successachieved through the use of coated products, pre-oxidation, or chemicaladditives to reduce filamentous (catalytic) coking in light feedstockolefins furnaces has generally been limited to a 2-3 fold improvement inrun-length at best, over industry surveyed run-lengths that werepresented at the AIChE Ethylene Producers' Conference in 1995. Mostrecently, NOVA Chemicals (see U.S. Pat. Nos. 5,630,887, 6,436,202,6,824,883, and 6,899,966) has achieved run-lengths in excess of 400 days(better than a 10-fold improvement in runlength) with a gas treatmenttechnology based on generating a [Cr—Mn]-spinel surface on the steelcomponents, and SK (see U.S. Pat. Nos. 6,514,563 and 6,852,361) hasachieved a 3-4 fold improvement with an in-situ coating applicationtechnology.

The selection and use of protective surface oxides on stainless steelsby the above teachings is illustrated in Table 1 hereinbelow (seeMetallurgical and Materials Transactions A Vol. 11 Number 5, May 1980Tritium permeation through clean incoloy 800 and sanicro 31 alloys andthrough steam oxidized incoloy 800 Author(s): J. T. Bell; J. D. Redman;H. P. Bittner Pages: 775-782; and Analysis of oxide coatings onsteam-oxidized incoloy 800 Author(s): H. F. Bittner; J. T. Bell; J. D.Redman; W. H. Christie; R. E. Eby Pages: 783-790) with efforts aimed atgenerating surface species more thermodynamically stable than chromia.Commercially-available furnace products used in the manufacture ofpetrochemicals have focused mainly on providing a chromia, silica,alumina or a [Cr—Mn]-spinel scale in contact with the hydrocarbonprocess stream.

TABLE 1 Relative Oxide Stability of Austenitic Stainless SteelComponents from Free Energies of Formation Data Oxide −ΔG° × 10⁻⁴(cal/mole O₂) at 900 K NiO 7.45 Fe₂O₃ 9.35 Fe₃O₄ 9.85 FeO 9.88 Mn₂O₃11.58 Mn₃O₄ 12.78 FeCr₂O₄ 13.34 Cr₂O₃ 14.35 MnCr₂O₄ N/A MnO 15.26 SiO₂17.10 Ti₂O₃ 20.19 Al₂O₃ 22.15

In summary, the prior art related to materials solutions (coatings,modified base alloy formulations, or pre-oxidation) to the coking,catalytic activity and corrosion problem in petrochemical furnacesteaches that stainless steel alloy technology is based on generating achromia protective scale, and that recent teachings suggest that similaraustenitic HTAs can also be used to generate an alumina, silica or Cr—Mnspinel. Secondly, with the exception of the NOVA Chemicals[Cr—Mn]-spinel technology, the prior art teaches that efforts aimed atgenerating [Cr—Mn]-spinel based surfaces are of little commercial valuedue to their low thermo-mechanical stabilities and reduced protection tothe base alloy after any damage/delamination. Thirdly, it teaches thatcommercial coated products are based on the generation of a protectivealumina or silica scale with other properties that may be superior tothe same scale generated on uncoated alloys. Overall, all of the aboveteachings are aimed at enhancing the inertness of the surface to thecracking process.

The prior art relating to coatings aimed at enhancing the catalyticgasification properties of the surface teaches that carbon gasificationduring cracking is possible through the use of coatings but littlecommercial success has been realized to-date primarily due to suchproducts' inability to address survivability requirements under theextreme conditions present in olefins manufacture.

The disclosure hereinbelow capitalizes on the potential negative impacton the overall cracking process, despite the relatively low surface areaexposure to the overall process stream, and provides coatings andsurfaces that can eliminate the unwanted (negative) catalytic propertiesas one benefit, and simultaneously provide positive or beneficialcatalytic activity as a major new materials and process benefit to theindustry. Such coatings and surfaces can provide significant commercialvalue ranging from improvements in plant efficiencies and profitability,to reducing energy requirements, steam dilution requirements and overallgreenhouse gas emissions.

The disclosure hereinbelow involves the application offunctionally-graded coatings that sustain surfaces with positivecatalytic activity, and a range of catalyst formulations and surfaceloading integrated into commercially-viable coating systems usingcurrent industry furnace alloys. Two families of surfaces have beendeveloped, providing a significant range of catalytic functionalityimpacting the process, as well as a coating system aimed at ensuringcommercial viability. The coatings are best described as composites,consisting of metallic, intermetallic and ceramic constituents, andexclude expensive constituents such as precious metals. It is recognizedthat olefins furnaces represent some of the most extreme hightemperature and corrosive conditions of any industrial manufacturing andrepresent serious challenges to commercial-scale viability. Overall, thedisclosure herein aims to provide additional chemical, physical andthermo-mechanical properties in its coatings to achieve commercialviability.

SUMMARY

Various embodiments of this disclosure involve the deposition of a Mnand W-based coating matrix on a range of alloy steel components, capableof generating and sustaining up to two groups of catalytic surfaces:

-   Mn-based Surfaces: MnO, MnO₂, Mn₂O₃, Mn₃O₄, MnCr₂O₄-   W-based Surfaces: CaWO₄, Ba₃Y₂WO₉

The Mn-based surfaces of described in this disclosure capitalize on thegreater thermodynamic stability of the oxides MnO and MnCr₂O₄ spinel,relative to chromia, and the ability to control the kinetics ofoxidation to set-up oxide growth conditions that results in protectiveoxide surface systems (protective surfaces) with good chemical andthermo-mechanical stability for commercial utility in severepetrochemical furnace environments. The Mn-based surfaces include:

MnO, MnO₂, Mn₃O₄, Mn₂O₃, MnCr₂O₄

These surfaces can be generated from the functionally-graded coatingsystem generated as described below and capable of providing underpyrolysis (cracking) conditions, an outermost surface composition incontact with the hydrocarbon process fluid stream that providescatalytic gasification of carbon, high resistance to filamentous(catalytic) coking, and enhanced corrosion protection. This disclosureinvolves at least four elements to help achieve commercial utility:

-   -   Base material or steel alloy selection    -   Coating formulation and application    -   Coating consolidation with base alloy by heat treatment    -   Surface generation and catalytic activation

According to one embodiment, a coating composition is disclosed. Thecoating composition comprises: Mn_(x)O_(y), MnCr₂O₄, or combinationsthereof in a first region of a coating having a first thickness, whereinx and y are integers between 1 and 7; and X₆W₆(Si_(z), C_(1-z)) in asecond region of the coating having a second thickness, wherein X is Nior a mixture of Ni and one or more transition metals and z ranges from 0to 1.

According to another embodiment, a coating is disclosed. The coatingcomprises: a first region having a first thickness, wherein the firstregion comprises Mn_(x)O_(y), MnCr₂O₄, or combinations thereof, whereinx and y are integers between 1 and 7; and a second region having asecond thickness, wherein the second region comprises X₆W₆(Si_(z),C_(1-z)), wherein X is Ni or a mixture of Ni and one or more transitionmetals and z ranges from 0 to 1.

According to another embodiment, a substrate coated with theabove-described coating is disclosed. The substrate can be made fromaustenitic steel, a nickel based alloy, an iron based alloy, and/or anickel-iron based alloy. The substrate can be a cracking coil, quenchexchanger, or other downstream equipment used for olefin production orsteam pyrolysis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is a scanning electron micrograph (hereinafter “SEM”) of earlystage growth of a coke deposit.

FIG. 1b is a SEM of late stage growth of a coke deposit.

FIG. 2 is a SEM of a cross section of a catalytic coating according toan embodiment.

FIG. 3 is a SEM of a top view of the low catalytic gasifier (hereinafter“LCG”) surface comprising Mn-based coating with W.

FIG. 4 is a flow diagram of a method according to an embodiment.

FIG. 5 is a plot comparing the overall coking-rate within a pilotpyrolysis test circuit as a function of sulfur level for ethanecracking, 65% conversion, 0.3:1 steam:hydrocarbon ratio of an embodimentwith an uncoated 35C5-45Ni—Fe alloy.

FIG. 6 is a plot comparing the overall coking-rate within a pilotpyrolysis test circuit as a function of sulfur level for butanecracking, 95% conversion, 0.4:1 steam:hydrocarbon ratio of an embodimentwith an uncoated 35C5-45Ni—Fe alloy.

FIG. 7 is a plot comparing the pressure drop of an embodiment with anuncoated 35C5-45Ni—Fe alloy.

FIG. 8 is a bar chart comparing the days online of an uncoated35C5-45Ni—Fe alloy with three samples of an embodiment.

FIG. 9 is a plot illustrating a thermogravimetric analysis (hereinafter“TGA”) comparison of an embodiment with an uncoated substrate.

FIG. 10 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample collected in an atmosphere of 10 ml/min airand 38 ml/min Ar.

FIG. 11 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample at 600° C., under an atmosphere of 10 ml/minair and 38 ml/min Ar.

FIG. 12 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample collected under lower oxidation potentialatmosphere, 2% H₂O in Ar.

FIG. 13 shows coking resistance of the present coatings for ethanecracking compared to monolithic alumina, a chromia-based surface (onKHR45A alloy—a 35Cr-45Ni—Fe alloy) and nickel.

FIG. 14(a), FIG. 14(b), FIG. 14(c), and FIG. 14(d) show graphs of thelaboratory evaluation of the stability of candidate catalysts undersulfur exposure at elevated temperatures: FIG. 14(a) shows Mn-basedcandidate catalyst XRD before and after S exposure; FIG. 14(b) showsW-based candidate catalyst XRD before and after S exposure; FIG. 14(c)shows Mn-based candidate catalyst TGA gasification efficacy before andafter S exposure; FIG. 14(d) shows W-based candidate catalyst TGAgasification efficacy before and after S exposure.

FIG. 15(a) shows a graph of XRD results of MnO sample before and after1150° C. 100 hr test under high carbon activity condition. FIG. 15(b)shows a graph of XRD results of Cr₂O₃ sample before and after 950° C.100 hr test under high carbon activity condition. FIG. 15(c) shows agraph of XRD results of MnCr₂O₄ sample before and after 950° C. 100 hrtest under high carbon activity condition

FIG. 16 shows a graph of the laboratory results of carbon gasificationpropensity of select reference materials, and the Mn-based and W-basedcatalyst species of this disclosure.

FIG. 17(a) and FIG. 17(b) show tables that summarize laboratory steampyrolysis results using ethane feedstock over select referencematerials, and the Mn-based catalyst species and W-based catalystspecies of this disclosure.

FIG. 18(a) and FIG. 18(b) show tables that summarize laboratory steampyrolysis results using a Heavy blend feedstock: FIG. 18(a) Referencerun and FIG. 18(b) run with use of Mn-based catalyst surface and runwith using a combined Mn-based catalyst surface (high surface coverage)and a W-based catalyst surface (low surface coverage).

FIG. 19 shows a SEM of typical set of micro-hardness indentation(H_(v)4.9N) in the cross-sectional sample of the invented coating.

FIG. 20(a) and FIG. 20(b) show bar charts summarizing laboratory steampyrolysis results using ethane feedstock of coupon samples: FIG. 20(a)run with reference materials; and FIG. 20(b) run with use of Mn-basedcatalyst surface (high surface coverage) and run with using a combinedMn-based catalyst surface (high surface coverage) and a W-based catalystsurface (low surface coverage).

DETAILED DESCRIPTION

Olefin production through stream cracking is highly energy and capitalintensive. One detrimental consequence of the cracking process is theformation of coke. Coke deposits in cracking coils, quench exchangers,and other downstream equipment which results in: loss of heat transferand thermal efficiency, carburization of coils and components, highmaintenance costs and reduced furnace availability, high pressure dropand reduction in furnace throughput, and reduced production yield.Embodiments of the disclosure include coatings and coating methods thatcatalyze carbon gasification reactions, thereby reducing the build up ofcoke in cracking coils, quench exchangers and other downstreamequipment.

FIGS. 1a and 1b illustrate the catalytic formation of coke in aconventional uncoated cracking coil. Nickel and iron in the bulk tubemetal (typically austenitic steel) act as catalysts for coke formation.FIG. 1a illustrates early stage coke formation. In this stage, cokegrows as hair-like filaments with an active nickel or iron particle atthe tip. In the later stages of growth, illustrated in FIG. 1b , thefilaments grow laterally into each other and continue to lengthen. Theresult is a thick porous carbon coating.

In an embodiment (shown in FIG. 2), the catalytic coating 100 has twodistinct regions. A first (top) region 102 is the outermost region ofthe catalytic coating 100. This region is exposed to the atmosphere.Underlying the first region 102 is a second region 104. The secondregion 104 is immediately adjacent the substrate 106. The substrate 106may be, for example, a cracking coil, quench exchanger, or otherdownstream equipment used for olefin production or steam pyrolysis. Thecatalytic coating 100 may additionally be used to protect pipe andequipment for other, non-olefin production processes in which cokeformation is undesirable. The substrate 106 may be, for example, anaustenitic steel, a nickel based alloy, an iron based alloy, or anickel-iron based alloy.

The first region 102 may have a thickness of 0.5-20 microns in oneembodiment. In another embodiment, the first region 102 may have athickness of 1-10 microns. In an embodiment, the first region maycomprise manganese oxides or chromium-manganese oxides or combinationsof one or more manganese oxides and/or chromium-manganese oxides.Manganese oxides have the general formula Mn_(x)O_(y), where x and y areintegers. Example manganese oxides include MnO, Mn₂O₃, Mn₃O₄, and MnO₂.Chromium-manganese oxides include but are not limited to MnCr₂O₄.

In an embodiment, the second region 104 may have a thickness of 100-1000microns. In another embodiment, the second region 104 may have athickness of 200-500 microns. The second region 104 typically includestwo or more phases 108, 110. In one embodiment, the first phase 108(“white” in FIG. 2) has a stoichiometry of X₆W₆(Si_(z), C_(1-z)) “661”,where X comprises Ni or a mixture of Ni and one or more transitionmetals and z ranges from 0 to 1. The transition metal may be, forexample, Fe, Nb, Cr, Mn, Ti, and/or combinations of these metals. Inanother embodiment, the first phase 108 has a stoichiometry ofXW(Si_(z), C_(1-z)) “111.” Alternatively, the first phase 108 may be amixture of “661” and “111.” The second phase 110 (dark in FIG. 2) may bedesignated as the matrix.

In an embodiment, the overall composition of the second region 106includes, Ni in a range of 10-45 wt %, Mn in a range of 1.5-12 wt %, Fein a range of 2-10 wt %, Si and/or C in a range of 5-10 wt %, W in arange of 35-80 wt %, and Cr in a range of 0.5-5 wt %, Nb in a range of0-2 wt %, and Ti in a range of 0-2 wt %. The composition of the secondphase (matrix) 110 may be ascertained by determining the amount andcomposition of the first phase 108 and subtracting from the overallcomposition of the second region 106. The first phase 108 may comprises40-80% of the second region 104.

In another embodiment, the first region 102 of the catalytic coating 100may include a calcium-tungsten oxide (CaWO₄), or abarium-yttrium-tungsten oxide (Ba₃Y₂WO₉), or combinations of acalcium-tungsten oxide and a barium-tungsten-yttrium oxides in additionto the manganese oxides and/or chromium-manganese oxide. In anembodiment, the CaWO₄ and/or Ba₃Y₂WO₉ may comprise 1-40% of the firstregion. The catalytic gasification of this embodiment may exceed thecatalytic gasification of an embodiment without CaWO₄ and/or Ba₃Y₂WO₉.

The SEM in FIG. 3 illustrates the top view of the LCG surface comprisingMn-based coating with W. The oxide shown represents a small, closelypacked crystal structure which is highly desirable from athermo-mechanical property perspective due to its high stability in thedesired application.

Another embodiment relates to methods of coating 400 an object with acatalytic coating (see FIG. 4). In one aspect, the method includes astep of forming a mixture of metal powders 404. The mixture of metalpowders may include Ni in a range of 10-45 wt %, Mn in a range of 1.5-12wt %, Fe in a range of 2-10 wt %, Si and/or C in a range of 5-10 wt %, Win a range of 35-80 wt %, and Cr in a range of 0.5-5 wt %, Nb in a rangeof 0-2 wt %, and Ti in a range of 0-2 wt %. The powders may be inelemental form and processed (e.g., screened) to have a sizedistribution having d50 of <10 microns. In another aspect, the sizedistribution has a d50 preferably <7 microns. In another aspect, thesize distribution has a d50 preferably <5 microns.

In one aspect, the powders are pre-conditioned to make them reactive402. To make the powders reactive, the powders may be exposed to areducing agent to remove oxide on the surface of the powders. Reductionof the oxide may be performed by exposing the powders to heatedhydrogen, electrochemically or by any other method known in the art. Insome embodiments, all of the powder is made reactive. In otherembodiments, only a portion of each of the powders is made reactive. Insome embodiments, the portion of each powder that is made reactive maybe, for example 50%, 25%, 10%, 5%, 2% by weight. That is, the portion ofeach powder that may be made reactive may be between 0-50% by weight.The individual powders may be pre-conditioned prior to mixing.Alternatively, some or all of the powders may be mixed and then subjectto a pre-conditioning treatment.

The method also includes a step of conducting a first heat treatment ata first temperature after the mixing the powders. The first heattreatment 406 is preferably conducted at a temperature above 250° C.Alternatively, the first heat treatment 406 may be conducted at atemperature above 350° C. In another embodiment, the first heattreatment 406 may be conducted at a temperature above 400° C. The timefor the first heat treatment 406 will vary with temperature; the hotterthe heat treatment temperature, the less time is used for treatment. Thefirst heat treatment 406 is preferably conducted in a vacuum or an inertatmosphere. The inert atmosphere may be, for example, argon, neon,helium, or combinations of these gases. The first heat treatment 406partially stabilizes the powder mixture.

In the next step, the partially stabilized powder mixture is applied tothe object to be coated 408. Application of the partially stabilizedpowder mixture 408 may be performed, for example, by spray coating, dipcoating, or any other coating method. Depending on the applicationprocess selected, the partially stabilized powder may be liquid form, aspray form, or a quasi-solid form.

After the object is coated 408 with the partially stabilized powdermixture, the object is optionally allowed to dry 410. Next, a secondheat treatment is performed 412. The second heat treatment 412consolidates the coating. In the consolidation process, the powdermixture interdiffuses into a defined microstructure. The second heattreatment 412 is preferably conducted in a vacuum and/or in an inertatmosphere. The inert atmosphere may be, for example, argon, neon,helium, or combinations of these gases. The concentration of reactivegases such as oxygen and nitrogen should be kept low. In one aspect, avacuum is first drawn and then 1-2 torr of argon is introduced to thevacuum chamber.

After the second consolidation heat treatment 412, a controlledoxidation is performed 414. In the controlled oxidation 414, the coatingis heated in the presence of oxygen. Depending on the oxygenconcentration, the temperature and the time of the controlled oxidation,different oxide compositions, crystal structures and morphologies can beproduced.

In an alternative embodiment, the method includes a step of doping 416the first regions 102 of the coating 100 with CaWO₄ and/or Ba₃Y₂WO₉.Doping 406 may be performed, for example, by introducing a solcontaining, for example, CaO and WO₃ while the oxide grows. Doping istypically performed at elevated temperatures but below 800° C. In anembodiment, the sols can be introduced into a gas stream as the oxidegrows. Other methods of doping the first regions 102 of the coating 100with CaWO₄ and/or Ba₃Y₂WO₉ may also be used.

Another embodiment relates to an object 106 having a catalytic coating100 (FIG. 2). In one aspect, the catalytic coating 100 includes a firstregion 102 having a first thickness and comprising Mn_(x)O_(y), MnCr₂O₄,or combinations of these oxides, where x and y are integers and a secondregion 104 having a second thickness and comprising a first phase 108and a second phase 110. The first phase 108 includes X₆W₆(Si_(z),C_(1-z)), where X is Ni or a mixture of Ni and one or more transitionmetals while z ranges from 0 to 1. The second region 104 generally hasan overall composition including Ni in a range of 10-45 wt %, Mn in arange of 1.5-12 wt %, Fe in a range of 2-10 wt %, Si and/or C in a rangeof 5-10 wt %, W in a range of 35-80 wt %, and Cr in a range of 0.5-5 wt%, Nb in a range of 0-2 wt %, and Ti in a range of 0-2 wt %.

The thickness of the first region 102 may be 0.5-20 microns. In anotherembodiment, the first region 102 may have a thickness of 1-10 microns.In an embodiment, the second region 104 may have a thickness of 100-1000microns. In another embodiment, the second region 104 may have athickness of 200-500 microns. The second region 104 typically includestwo or more phases 108, 110. In one embodiment, the first phase 108 hasa stoichiometry of X₆W₆(Si_(z), C_(1-z)) “661”, where X comprises Ni ora mixture of Ni and one or more transition metals and z ranges from 0to 1. The transition metal may be, for example, Fe, Nb, Cr, Mn, Ti,and/or combinations of these metals. In another embodiment, the firstphase 108 has a stoichiometry of XW(Si_(z), C_(1-z)) “111.”Alternatively, the first phase 108 may be a mixture of “661” and “111.”The second phase 110 may be designated as the matrix.

In an embodiment, Mn_(x)O_(y) may include MnO, Mn₂O₃, Mn₃O₄, and MnO₂.Additionally, the first phase 108 may comprise 40-80% of the secondregion 104.

In an alternative embodiment, the first region 102 of the coating 100further includes CaWO₄, Ba₃Y₂WO₉, or combinations of these oxides. Inone aspect, the CaWO₄, Ba₃Y₂WO₉, or combinations may comprises 1-40% ofthe first region 102.

Coatings that are functionally-graded in depth have been developed formetal alloy components susceptible to carbon-based fouling (coking),corrosion and erosion in hydrocarbon processing at elevatedtemperatures. The coatings generate and sustain surfaces thatcatalytically gasify carbonaceous matter, are inert to filamentous-cokeformation, and overall provide a net positive economic impact tohydrocarbon manufacturing processes. Additionally, the coatings provideprotection to the base alloy from various forms of materials degradationinclusive of high temperature oxidation, carburization, and erosion. Thecoatings are functionally-graded to achieve both the outermost surfacecatalytic properties required, and a broad range of chemical, physicaland thermo-mechanical properties needed to survive the severe operatingconditions of hydrocarbon processing, specifically, petrochemicalsmanufacture that can exceed 800° C.

Commercial applications of such coatings include furnace components usedto manufacture major petrochemicals such as olefins by hydrocarbon steampyrolysis in which temperatures may exceed 1100° C. These coatings andsurfaces have been demonstrated to increase operating efficiency bygasification of carbonaceous deposits, reducing filamentous cokeformation, and positively impacting the overall pyrolysis process andproduct stream. As an example, in the pyrolysis of aliphatic feedstocksto produce mainly ethylene, the low-coking environment provided by thisdisclosure can reduce carbon-based fouling to temperatures of 1100° C.depending on cracking severity and feedstock, with a neutral or positiveimpact on product yields. The benefits of the disclosure can be utilizedcommercially by providing a significant range of new operating regimesas described in Table 2.

TABLE 2 Lighter (Ethane/Propane) Heavier (Butane/Naphtha) HydrocarbonFeedstocks Hydrocarbon Feedstocks Current Potential Current PotentialCommercial Range Commercial Range Potential Benefits Range of Use Rangeof Use Operating Run Length 10-90 days 20 to 500+ days 10-90 days20-200+ days Feedstock Conversion 50 to 75% 60 to 90+% 60-85% 60-90+%Steam Dilution 0.28 to 0.33 0.18 to 0.33 0.40 to 0.60 0.30 to 0.60 (askg steam:kg hydrocarbon) Operating Tube Metal 1000-1150° C. 10 to 50° C.950-1150° C. 10 to 50° C. Temperature (TMT) lower in lower in averageTMT average TMT

The selection of a base alloy composition compatible with the operatingenvironment and also compatible with coating formulation for generatingtargeted microstructures is considered. Ideally the base alloy is anaustenitic stainless steel with at least 8 wt % Ni, preferably greaterthan 20 wt % Ni and most preferably greater than 40 wt % Ni. The balanceof other elements in the austenitic steel is defined by operatingconditions requirements, and the coating formulation can be adjusted tocompensate for commercial ranges of Fe, Cr, and microalloying levels.

Coating formulation and application is possible by a range of coatingtechnologies such that material of the compositional range in the tablebelow is delivered to the surface in a uniform manner with a finalthickness after consolidation of a minimum of 10 microns and a maximumof 5,000 microns. The coating constituents need to be delivered in astate of high reactivity to allow subsequent interdiffusion and alloyingwith the base alloy steel components during controlled-atmosphere heattreatment consolidation. Coating formulation is tailored to the basealloy composition and the targeted surface properties. Typical rangesfor the key constituents in the coating after consolidation are asfollows in Table 3:

TABLE 3 Coating Constituents Range Average Chromium 10-30 wt % 20 wt % *Iron  1-20 wt % 10 wt % * Nickel 10-50 wt % 25 wt % * Tungsten  5-60 wt% <30 wt % Manganese  2-30 wt % <15 wt % Silicon  2-15 wt % <8 wt %Niobium  0-3 wt % <2 wt % Molybdenum  0-3 wt % <2 wt % Titanium  0-3 wt% <2 wt % Aluminum  0-3 wt % <2 wt % * denotes constituents providedprimarily by base alloy

Coating application can be undertaken by a range of techniques capableof delivering powder-based formulations to the surface of thecomponents. These include thermal spray-based processes and slurry-basedcoating methods. The preferred coating approach of this disclosure isslurry-based methods with additions of aqueous and organic componentsknown to those versed in the art and appropriate to the compositionalformulations noted in the table above.

Heat treatment for coating consolidation is undertaken under acontrolled inert atmosphere ranging from vacuum level through toelevated pressures. The pressure was found to not be critical, but thereduction of reactive species such as oxygen and nitrogen needs to becontrolled. The temperature of consolidation ranges from 900 to 1200°C., depending on the base material or steel alloy composition, coatingformulation and the targeted coating microstructure.

Following heat treatment consolidation, the coating is prepared forfinal surface generation and catalyst activation. Standard cleaningprocedures can be used to achieve the desired level of surfacecleanliness and surface finish. An initial hydrogen treatment is used toreduce surface oxide species and remove carbonaceous contaminants suchas organic cutting fluids.

Stage I: Reduction and Cleaning

-   Hydrogen species: H₂-   Carrier gas/diluent none, nitrogen, or argon-   Temperature 400 to 1000° C.-   Time: 2 to 24 hours    Stage II: Oxidation and Catalytic Activation-   Oxygen-bearing species: air, O₂, CO₂, steam-   Carrier gas/diluent: none, nitrogen, or argon-   Temperature: 800 to 1100° C.-   time: 4 hours to 100 hours

EXAMPLES

FIG. 5 is a plot comparing the overall coking-rate within a pilotpyrolysis test circuit as a function of sulfur level for ethanecracking, 65% conversion, 0.3:1 steam:hydrocarbon ratio of an embodimentwith an uncoated 35Cr—45Ni—Fe alloy. As can be seen in FIG. 5, anincrease in the sulfur content of the ethane in an uncoated reactorresults in a significant increase in the coking rate. Sulfur levels aslow as 100 ppm result in an almost five fold increase in the rate ofcoke formation absent sulfur. With the use of a coating according to anembodiment having manganese oxides and chromium-manganese oxides,however, the rate of coke formation remains essentially constant.

FIG. 6 is a plot comparing the overall coking-rate within a pilotpyrolysis test circuit as a function of sulfur level for butanecracking, 95% conversion, 0.4:1 steam:hydrocarbon ratio of an embodimentwith an uncoated 35Cr—45Ni—Fe alloy. The results for butane cracking aresimilar to the results for ethane cracking illustrated in FIG. 5. Thatis, use of a coating according to an embodiment having manganese oxidesand chromium-manganese oxides, results in a coking rate that isinsensitive to the sulfur content of the butane while an uncoatedreactor suffers a significant increase in the coking rate as a functionof sulfur content.

FIG. 7 is a plot comparing the pressure drop of an embodiment with anuncoated 35Cr—45Ni—Fe alloy. In this embodiment the first region 102 ofthe coating 100 includes manganese oxides and chromium-manganese oxides.After 30 hours, the uncoated pipe begins to suffer an increasingpressure drop while the pressure in the coated pipe remains constant.The pressure drop is an indication of a growing coke layer in theuncoated pipe.

FIG. 8 is a bar chart comparing the results of experiments of threesamples of an embodiment with a conventional uncoated 35Cr—45Ni—Fe alloyfurnace coils. Conventional furnace coils used in ethane processing canonly stay online for approximately 30 days before being clogged withcoke. The first sample ran for 125 days before being shut down for anunrelated instruments anomaly. Analysis of the furnace coils indicated aprojected service life of over 300 days. The second sample ran for 124days before being shut down for a plant shutdown. Analysis of thefurnace coils indicated a projected service life of over 300 days. Thethird has run for 254 days and is also projected to have a service lifeover 300 days without the need to de-coke.

FIG. 9 is a plot illustrating a TGA comparison of an embodiment with anuncoated substrate. The coating 100 of this embodiment included CaWO₄ orBa₃Y₂WO₉, in addition to manganese and chromium-manganese oxides. Thetime-temperature ramp is shown on the x-axis. The y-axis shows theweight loss of graphite due to gasification. The test atmosphere wassteam/argon which provided an overall low oxidizing potential. The topprofile 902 is a reference run with graphite and no catalyst and showsan Onset Temperature of Gasification of ˜1032° C. (1890° F.) 904. Thelower profile 906 is graphite plus catalyst showing an Onset Temperatureof Gasification of ˜872° C. 908 and higher gasification rate.

Example 1 Laboratory-scale Demonstration of Gasification of Carbon (forW-based Oxide Surfaces)

This example demonstrates the catalytic function of the Mn-basedcomponents in promoting carbon gasification. The tests were conducted ona Mettler-Toledo TGA/SDTA 850 system under a controlled atmosphere.Commercial Graphite powder (CERAC, 99.5% purity, −325 mesh) was used asthe carbon indicator. In each test, the graphite powder and the powderof the testing sample were weighed and blended in an alumina crucible,and then placed onto the sample holder of the Mettler-Toledo TGA/SDTA850 system. During the test the sample temperature was programcontrolled and monitored, and the sample weight was continuouslymeasured and plotted as a function of temperature and time. The onsettemperature of the TGA curve indicates the initial temperature of thecarbon gasification event, and the step size indicates the amount of theweight loss of the graphite powder that is the amount of graphite hasbeen gasified. Runs with graphite powder without addingMn-based-components were used as non-catalytic carbon gasificationreferences.

Graphite and blended CaWO₄/graphite samples were tested under anatmosphere of high oxidation potential (10 ml/min Air and 38 ml/min Ar),with a temperature program of ramping from 100 to 1100° C. at a rate of30° C/min and holding at 1100° C. for 10 minutes. The results are shownin FIG. 10. It shows that the TGA curve of the blended CaWO₄/graphitesample has a lower onset temperature and a larger weight loss step thanthe reference curve of graphite.

FIG. 10 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample collected in an atmosphere of 10 ml/min airand 38 ml/min Ar.

A separate set of experiments was carried out at 600° C. under the samehigh oxidation potential atmosphere for 1 hour. The results are shown inFIG. 11. It shows that the level of carbon gasification (graphite weightloss: 1.38%) under such conditions is insignificant without catalyst.The TGA curve of the blended CaWO₄/graphite sample shows a step of36.88% graphite weight loss that demonstrates the catalytic activity ofCaWO₄ at lower reaction temperature.

FIG. 11 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample at 600° C., under an atmosphere of 10 ml/minair and 38 ml/min Ar.

Lower oxidation potential tests were conducted with the addition of 2%H₂O in Ar with a temperature program of ramping from 100 to 1100° C. ina rate of 30° C./min and holding at 1100° C. for 10 minutes. The resultsare shown in FIG. 12. Under such conditions, the onset temperature ofthe graphite reference sample is 1032.14° C., and the step of weightloss is only 1.96% while the blended CaWO₄/graphite sample shows a muchlower onset temperature, 870.81° C., and a much larger step of weightloss, 16.66% that demonstrates the catalytic activity of CaWO₄ underlower oxidation potential atmosphere.

FIG. 12 shows TGA curves of the blended CaWO₄/graphite sample and thegraphite reference sample collected under lower oxidation potentialatmosphere, 2% H₂O in Ar.

Example 2 Laboratory Demonstration of Surface Inertness to FilamentousCoke Generation

This example demonstrates the inertness of the invented coating(Mn-based surface). Coking resistance property has been tested on threeMn-based surface coating samples and three reference samples, alumina,oxidized KHR45A alloy, and nickel coupons. Among the three referencesamples, nickel is a well known catalyst for making filamentous coke,and alumina represents an inert surface to coke formation. KHR45A is ahigh temperature alloy with the composition of 35% Cr—45% Ni—Fe(balance). It was pre-oxidized at 850° C. in air for 8 hours to generatea surface dominated with chromium oxide, Cr₂O₃ that is inert tocatalytic coke formation. The three Mn-based surface coating samplesdoped with 3.81, 7.62 and 15.42 wt % Mn were also oxidized under thesame conditions to generate manganese oxide surfaces.

The coking resistance evaluation test was carried out at a bench-topsteam pyrolysis test rig with the six sample coupons placed in thecenter of a quartz tubular reactor. With Ar purging, the reactor washeated in a furnace set at a temperature of 800° C. Upon reaching settemperature, steam and ethane was introduced into the reactor at a rateof 100 ml/min ethane with the ratio of steam to ethane controlled at 1to 3. After a run of 1 hour, the feeding of ethane and steam wasdiscontinued, and the reactor was cooled down with Ar purging. Upon thetermination of the run, it was evident that substantial coke wasaccumulated on the surface of the nickel sample but not on the rest ofthe samples. The weight increase of sample reflects the amount of cokedeposits on its surface and thus was used for coking rate calculation.The test results, listed in Table 4 and plotted in FIG. 13, show thatthe inertness of the invented coatings is compatible to alumina andchromium oxide surfaces.

TABLE 4 Testing Surf. Area Coking Rate Materials Surface (cm²)mg/cm²/hour Al₂O₃ Al₂O₃ 3.85 0.00 Mn (3.81%) Mn₂O₃ 5.00 0.06 Mn (7.62%)Mn₂O₃ 5.07 0.02 Mn (15.42%) Mn₂O₃ 5.01 0.12 KHR45A Cr₂O₃ 5.43 0.11 Ni Ni2.40 9.82

Example 3 Stability of Catalyst Materials Under Elevated Temperature,High Sulfur Exposure Showing: (a) by XRD, No Changes in CrystalStructure or Decomposition; (b) by TGA, no Detectable Loss in CatalyticEfficacy of Gasification

In this example the stability of candidate catalysts under sulfurexposure at elevated temperatures has been evaluated. Powder samples ofcandidate catalysts were treated in a tubular quartz reactor under anatmosphere of 25% H₂O and 75% Ar. The reactor was heated in a furnaceset to 900° C. Once reaching the set temperature, a syringe infusionpump fed dimethyl disulfide (DMDS) into the reactor providing 500 ppmsulfur in the gas stream. The duration of sulfur exposure was 4 hoursand the sample temperature was monitored throughout the run with athermocouple inserted inside the reactor and attached to the sampleholder. All samples were examined by XRD and tested for carbongasification activity, by the method described in Example 1 (the numberto be changed along with the example's final location), before and afterthe sulfur treatment. The results of Mn-based candidate catalyst areshown in FIG. 14(a) and FIG. 14(c), and W-based candidate catalysts areshown in FIG. 14(b) and FIG. 14(d). There are no noticeable phasechanges and carbon gasification activity changes for both Mn-based andW-based candidate catalysts.

Example 4 Thermal Stability of MnO Surface Under High Carbon ActivityConditions

In this example MnO has been evaluated for its thermal stability underhigh carbon activity conditions.

The testing sample powder, MnO, was mixed with commercial graphitepowder (CERAC, 99.5% purity, −325 mesh) in a ratio of 40 wt % MnO and 60wt % Graphite and placed in a ceramic boat. Extra graphite powder wasused to fully cover the top surface of the testing mixture to provide atesting environment of carbon activity, α=1. Following that, the boatwas covered by an alumina plate and placed in the center of a tubularceramic reactor. The test conditions were controlled at a pressure of1-2 torr Ar with an Ar flow rate of 70-85 ml/min. The ceramic reactorwas heated in a furnace programmed for 100 hours at 1150° C. The powdersample was examined by X-ray diffraction (XRD) analysis before and afterthe test, and the results are shown in FIG. 15 (a). It demonstrates thatMnO is chemically and structurally stable after 100 hours at 1150° C.under high carbon activity.

As comparison, the test results of reference samples, Cr₂O₃ and MnCr₂O₄,at 950° C. for 100 hours are shown in FIGS. 15(b) and (c), respectively.The formation of carbides has been detected for both reference samples.It can be concluded that the thermal stability of MnO under high carbonactivity is at least 200° C. higher than that of Cr₂O₃ and MnCr₂O₄.

FIG. 16 shows a graph of the increased gasification of carbon of theCAMOL materials (4) & (5) when compared to other oxides found in theindustry (2) & (3) and the reference (1).

FIG. 17(a) shows a table with an analysis of the effluent, includingcoke, of a reactor cracking ethane under standard conditions asindicated over two different high temperature alloys, one which is thetypically used as a reference (Modified 35Cr-45Ni—Fe Alloy).

FIG. 17(b) shows a table with an analysis of the effluent, includingcoke, of a reactor cracking ethane under standard conditions asindicated over two different Mn-based catalyst surfaces. Both of thesesurfaces show significantly lower coke make when compared to the hightemperature alloys in the table shown in FIG. 17(a).

The table shown in FIG. 18(a) shows an analysis of the effluent,including coke, of a reactor cracking a heavy liquid feedstock blend (asdefined) under standard conditions as indicated over several differenthigh temperature alloys, one which is the typically used as a reference(Modified 35Cr—45Ni—Fe Alloy). The machine polished surfaces show alower coke production than the typical oxide based surface which is moreindicative of the actual situation in industrial applications.

The table shown in FIG. 18(b) represents an analysis of the effluent,including coke, of a reactor cracking a heavy liquid feedstock blend (asdefined) under standard conditions as indicated over two differentMn-based catalyst surfaces. Both of these surfaces show significantlylower coke make when compared to the reference high temperature alloywith oxide in the table shown in FIG. 18(a) while maintaining similarcracking product composition and yields.

The SEM shown in FIG. 19 illustrates the integrated matrix of thecoating with the high temperature alloy substrate after the second heattreatment process. This represents the typical result of the coatingafter the manufacturing process.

FIG. 20(a) shows the coking potential of many oxides and metals inethane cracking service. This shows that most oxides have a much lowercoking potential than Iron and Cobalt-oxide, including the CAMOL oxideswhile maintaining similar cracking product composition and yields.

FIG. 20(b) shows the coking potential of different oxides, carbides andmetals in ethane cracking service. This shows that most oxides have amuch lower coking potential than Nickel and Nickel-oxide, including theCAMOL oxides while maintaining similar cracking product composition andyields.

Although the disclosure has been described in detail for the purpose ofillustration based on what is currently considered to be the mostpractical and preferred embodiments, it is to be understood that suchdetail is solely for that purpose and that the invention is not limitedto the disclosed embodiments, but, on the contrary, is intended to covermodifications and equivalent arrangements that are within the spirit andscope of the appended claims. For example, it is to be understood thatthe present invention contemplates that, to the extent possible, one ormore features of any embodiment can be combined with one or morefeatures of any other embodiment.

What is claimed is:
 1. A coating composition comprising: a manganeseoxide, a chromium-manganese oxide, or a combination thereof in a firstregion of a coating having a first thickness; and X₆W₆(Si_(z), C_(1-z))in a second region of the coating having a second thickness, wherein Xis Ni or a mixture of Ni and one or more transition metals and z rangesfrom 0 to
 1. 2. The coating composition of claim 1, wherein the secondregion has an overall composition comprising Ni in a range of 10-45 wt%, Mn in a range of 1.5-12 wt %, Fe in a range of 2-10 wt %, Si and/or Cin a range of 5-10 wt %, Win a range of 35-80 wt %, and Cr in a range of0.5-5 wt %, Nb in a range of 0-2 wt %, and Ti in a range of 0-2 wt %. 3.The coating composition of claim 1, wherein the first thickness is 1-10microns.
 4. The coating composition of claim 1, wherein the secondthickness is 200-500 microns.
 5. The coating composition of claim 1,wherein the transition metal comprises Fe, Nb, Cr, Mn, Ti, Mo, W, andcombinations thereof.
 6. The coating composition of claim 1, wherein thecoating further comprises CaWO₄, Ba₃Y₂WO₉, or combinations thereof.
 7. Asubstrate coated with the coating composition of claim
 1. 8. A substratehaving a surface, wherein the coating composition of claim 1 is providedas a coating on the surface of the substrate.
 9. The substrate of claim8, wherein the coating has a thickness of 200-500 microns.
 10. Thesubstrate of claim 8, wherein the coating is a first coating providedadjacent the surface and a second oxide coating is provided on the firstcoating opposite the surface, the second oxide coating comprising amanganese oxide, a chromium-manganese oxide, or a combination thereof.11. The substrate of claim 10, wherein the second oxide coatingcomprises a manganese oxide.
 12. The substrate of claim 10, wherein thesecond oxide coating has a thickness of 1-10 microns.
 13. The substrateof claim 10, wherein the second oxide coating further comprises CaWO₄,Ba₃Y₂WO₉, or a combination thereof.
 14. The substrate of claim 8,wherein the substrate is made from austenitic steel, a nickel basedalloy, an iron based alloy, and/or a nickel-iron based alloy.
 15. Acoating composition, comprising Ni in a range of 10-45 wt %, Mn in arange of 1.5-12 wt %, Fe in a range of 2-10 wt %, Si and/or C in a rangeof 5-10 wt %, W in a range of 35-80 wt %, and Cr in a range of 0.5-5 wt%, Nb in a range of 0-2 wt %, and Ti in a range of 0-2 wt %.
 16. Thecoating composition of claim 15, wherein the coating compositionincludes X₆W₆(Si_(z),C_(1-z)), wherein X is Ni or a mixture of Ni andone or more transition metals and z ranges from 0 to 1, wherein thetransition metal comprises Fe, Nb, Cr, Mn, Ti, Mo, W, or a combinationthereof.
 17. A method of preparing a coating on a substrate, comprising:applying a coating on a surface of a substrate, the coating comprisingNi in a range of 10-45 wt %, Mn in a range of 1.5-12 wt %, Fe in a rangeof 2-10 wt %, Si and/or C in a range of 5-10 wt %, Win a range of 35-80wt %, and Cr in a range of 0.5-5 wt %, Nb in a range of 0-2 wt %, and Tiin a range of 0-2 wt %; heating the coating in the presence of oxygen toform an oxide layer on a surface of the coating opposite the substratesurface, the oxide layer comprising a manganese oxide, achromium-manganese oxide, or a combination thereof.
 18. The method ofclaim 17, wherein heating the coating comprises heating the coating at atemperature of from 800° C. to 1100° C.
 19. The method of claim 17,wherein applying a coating comprises providing a mixture of metalpowders including Ni in a range of 10-45 wt %, Mn in a range of 1.5-12wt %, Fe in a range of 2-10 wt %, Si and/or C in a range of 5-10 wt %,Win a range of 35-80 wt %, and Cr in a range of 0.5-5 wt %, Nb in arange of 0-2 wt %, and Ti in a range of 0-2 wt %, pre-conditioning atleast a portion of the metal powders, applying the pre-conditioned metalpowders as a coating to the surface of the substrate.
 20. The method ofclaim 19, further comprising heating the coating in a vacuum or inertatmosphere to a temperature of from 900° C. to 1200° C. after thecoating has been applied to the surface of the substrate to consolidatethe coating with the substrate.